Concrete

Taking The Alternative Route

Published

4 years ago

January 14, 2022

admin

The cement industry can be leaders of change by taking the route of sustainability, using alternatives to conventional methods that shall positively impact the demand and meet goals set by global bodies. Kanika Mathur takes a deep dive into the various alternative fuels and raw materials the cement industry can depend upon to build a better and stronger future.

The world is going through a crisis. Natural resources are depleting, greenhouse gases are being emitted and pollution is on the rise. According to Fortune Business Insights, the global cement market is projected to grow from $326.80 billion in 2021 to $458.64 billion in 2028 at a CAGR of 5.1 per cent during the 2021-2028 period. The sudden rise is attributed to this market’s demand and growth, returning to the pre-pandemic levels once the pandemic is over.
In 2021, India also has chalked plans for infrastructural development like the ‘PM Gati Shakti – National Master Plan (NMP)’ for multimodal connectivity and is aiming for 100 smart cities. The Government also intends to expand the capacity of railways and the facilities for handling and storage to ease the transportation of cement and reduce transportation cost. These measures would lead to an increased construction activity, thereby boosting cement demand. The Union Budget allocated Rs. 13,750 crore (US$ 1.88 billion) and Rs. 12,294 crore (US$ 1.68 billion) for Urban Rejuvenation Mission: AMRUT and Smart Cities Mission and Swachh Bharat Mission, respectively and Rs. 27,500 crore (US$ 3.77 billion) has been allotted under Pradhan Mantri Awas Yojana, as published in the Indian Brand Equity Foundation Report for Indian Cement Industry Analysis 2021.
With the progressing economy and surging demand for cement and concrete, there is growth in infrastructure, but resources are getting exhausted by the day and the environment is facing that impact. It is imperative that an industry of this magnitude take steps by looking for alternative raw materials and fuels to meet the rising demand as well as protect natural reserves and nature on a whole.

Cement manufacturing process and conventional fuels and raw materials
All over the world, cement is one of the most important building materials. The process starts with extracting raw materials, crushing and transporting them to the manufacturing facility. The most important raw materials for making cement are limestone, clay and marl. These are extracted from quarries by blasting or by ripping using heavy machinery. Wheel loaders and dumper trucks transport the raw materials to the crushing installations. There the rock is broken down to roughly the size used in road metaling. It is then blended and homogenised, dried, and grinded.
The prepared raw material is then burned at approx. 1,450°C in a kiln. In this process, a chemical conversion takes place where carbon dioxide is emitted, and the product is the clinker.
Once the burnt clinker is cooled down, it is stored in clinker silos. From there the clinker is conveyed to ball mills or roller presses, in which it is ground down to very fine cement, with the addition of gypsum and anhydrite, as well as other additives, depending on the use to which the cement is to be put. The finished cement is stored in separate silos, depending on type and strength class.
The fuel used to heat the kiln is mainly coal which is a naturally occurring resource that is getting extinct by the day and also emits carbon. Similarly, limestone in the chemical process produces a large amount of carbon dioxide. This leads to the need of alternative raw materials and fuels in the cement manufacturing process.

Switching to alternative fuels and raw materials
Fuel is majorly required to heat the kiln. The products that would otherwise unrecyclable and may end up in landfills can serve as the perfect fuel for burning in the kilns. This would also mean disposing off the waste that may have polluted the land or sea.
By their nature, these fuels can be variable in quality, behaviour, moisture content and calorific value and will be difficult to convey, store, discharge and accurately dose into the fuel stream. Alternative fuels can help to reduce CO2 emissions.
Some of the widely used fuels that the industry is switching over to are: Refuse Derived Fuel (RDF), Solid Recovered Fuels (SRF), Wood, Waste Wood, Agricultural Waste, Tyre Derived Fuel, Meat and Bone Meal (MBM), Sewage Sludge Profuel, Chemical Residues, Oil Seeds, Municipal Solid Waste (MSW) and Sludge.
Leading cement manufacturing organisations have aligned themselves with the mission of the United Nations to achieve Net Zero Environment by 2050 and are on a pathway of creating greener solutions by switching to these fuels.
Saurabh Palsania, Executive Director, Dalmia Cement says “Cement industry has been using waste since its inception, be it fly ash or slag as an alternative fuel. Use of MSW in the cement industry is as good as fuel, but it comes with its own set of challenges. There are approximately 2000 sump sites and as per records there are about 1855 lakh tonnes of waste lying across India. The kilns in the cement industry that run at over 1300 degree Celsius can easily consume the waste and prevent it from ending up in landfills”.
“The industry has tie ups across multiple municipal corporations. We must improve our equipment and better utilise this available resource that can substitute carbon intensive fuels. We must also make this sector an organised sector for seamless operations” he adds.
Limestone makes up for 95 per cent of the raw material used in cement production. According to some estimates as mentioned by the Cement Manufacturers Association, around 180-250 kg of coal and about 1.5 tonne of limestone is required to produce a tonne of cement. Cement manufacturing also consumes minerals such as gypsum, Quartz, bauxite, coal, kaolin (china clay) and iron ore too in varying amounts.
Limestone is a naturally occurring mineral. Large amounts of limestone are calcified in cement manufacturing units to produce cement which leads to rapid depletion of this resource. It also emits a large amount of carbon dioxide in the process.
Cement industry has taken this into consideration and are moving towards materials like clay, chalk etc. to produce clinker that is less energy intensive and has reduced emission of carbon dioxide. These steps are important to ensure that the resource is conserved in nature and does not harm the environment as the chemical process cannot be changed. Organisations are constantly looking for innovations in the field of raw material and have employed experts in the field of alternative fuels and raw materials to come up with more sustainable solutions for this process.

Waste as an alternative to fuel and raw materials in the cement industry
Various types of cement have been introduced in the recent past by cement technologists the world over. Most of these cements have been developed by the addition of alternative waste (also known as SCM, supplementary cementitious materials) produced by other industries. Fly ash and various slags produced by metal industries are the two of the most significant components added as raw materials to the clinker production in cement kilns. Additionally, limestone is also used as a component of cement.
These additives are independently added as well as in combination in permissible percentages in the cement mixture along with clinker. Fly ash and GGBS slag are added in cement grinding to produce PPC and PSC cement. This combination of clinker, fly ash, and slag along with gypsum is used in cement grinding. The combinations of these three raw materials are based on the physical and chemical characteristics of the waste materials.
Similarly, organisations are working on supporting the circular economy concept and are collaborating with other organisations to collect various types of waste like plastic waste, agricultural waste, pharmaceutical waste etc. to use in the kilns and produce the required heat while substituting the role of coal in this process. This creates a huge impact on the environment in a positive manner as waste from the other industries does not pollute the land or water bodies and reduces the consumption of coal in cement making process.
According to Manoj Rustogi, Head – Sustainability, JSW Cement, “Wastage recovery is a very valid process in the alternative fuel and raw material context. As a policy intervention, recognising wastage recovery as a renewable power because there is no additional material used. It is the waste coming out from the cement making process that is used and tapped for electricity and power generation. 70 per cent of power requirement for clinker production can come from wastage recovery”.
“Another source of energy organisations must tap is solar energy. Combining the energy from waste recovery and solar power can take care of energy requirements of certain types of cements. A push from the government is required to adapt to this form of energy and it will surely take away a major chunk of carbon emission that we are currently dealing with” he adds.

Other efforts towards creating a sustainable environment
Leaders in cement manufacturing, organisations are taking the greener routes to keep the environment condition in check. From waste management facilities to rainwater harvesting and use of alternative fuels and raw materials, a lot of effort is being taken to develop a green economy.
Predicting the future of cement production, fuels and raw materials, SK Rathore, President, JK Cement says, “The world is now looking towards hydrogen as a green fuel. It is depending on how hydrogen is produced that makes it green and it is an expensive process. Another method of making cement greener and reducing the emission of carbon in the cement manufacturing process is the reduction of losses during clinker production with technological innovation”. He believes that development in these areas will be key in the near future and the cement industry will be quick to adapt to them for a better tomorrow and cleaner environment.
Pledging towards a net zero environment and building a better environment for the country is the goal of the cement industry in the decades to come. For this they are taking all efforts to look for alternative sources of energy as well as raw materials that does not compromise with the quality of the end product but also improves the operation process and gives least harm to the environment. Technical innovations and research in the area is sure to come up with solutions that will let the industry achieve their goals in the race to 2050.

Kanika Mathur

Up Next

Till bagged cement is in use, innovation will continue to happen

Don't Miss

The cement industry must lead the sustainable journey

Concrete

The primary high-power applications are fans and mills

Published

2 days ago

October 10, 2025

admin

Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how plants can achieve both cost competitiveness and sustainability by lowering emissions, reducing downtime and planning for significant power savings.

As one of the most energy-intensive industries, cement manufacturing faces growing pressure to optimise power consumption, reduce emissions and improve operational reliability. Technology providers like Innomotics India are enabling this transformation by combining advanced motors, AI-driven digital solutions and intelligent monitoring systems that enhance process stability and reduce energy costs. From severe duty motors built for extreme kiln environments to DigiMine AI solutions that optimise pyro and mill operations, Alex Nazareth, Whole-time Director and CEO, Innomotics India, explains how the company is helping cement plants achieve measurable energy savings while moving closer to their sustainability goals.

How does your Energy Performance Contracting model typically reduce power consumption in cement plants—e.g., MWh saved?
Our artificial intelligence-based DigiMine AI Pyro and Mill solutions developed specifically for the cement industry, supports our customers in improving their process stability, productivity and process efficiency. In Pyro, this is achieved by optimising fuel consumption (Coal / AFR), reducing Specific Heat Consumption and reduction in emissions (CO2, SOx and NOx) through continuous monitoring of thermodynamics in pyro and recommending set-points of crucial parameters in advance for maintaining stable operations.
Within the mill, this is achieved by improving throughput, reduce energy / power consumption and maintaining stable operations on a continuous basis. Our ROI-based value proposition captures the project KPIs like reduction of coal usage, increase of AFR, reduction of specific heat consumption (Kcal / Kg), reduction of specific power consumption (KWH / tonne), reduction of emissions, etc., by a specific percentage. This gives clarity to our customers to understand the investment vis-à-vis savings and estimate the recovery time of their investment, which typically is achieved within one year of DigiMine AI Pyro and Mill solutions implementation.

What role do digitalisation and motor monitoring play in overall plant energy optimisation?
Motors are being used extensively in cement production, and their monitoring play crucial role in ensuring continuous operation of applications. The monitoring system can automatically generate alerts for any anomaly / abnormalities in motor parameters, which allows plant team to take corrective actions and avoid any major equipment damage and breakdown. The alerts help maintenance team to plan maintenance schedule and related activity efficiently. Centralised and organised data gives overview to the engineers for day-to-day activities. Cement is amongst the top energy intensive industries in comparison to other industries. Hence, it becomes critically important to optimise efficiency, productivity and up-time of plant equipment. Motor monitoring and digitalisation plays a vital role in it. Monitoring and control of multiple applications and areas
within the plant or multiple plants becomes possible with digitalisation.
Digitalisation adds a layer on top of OT systems, bringing machine and process data onto a single interface. This solves the challenges such as system silo, different communications protocol, databases and most importantly, creates a common definition and measurement to plant KPIs. Relevant stakeholders, such as engineers, head of departments and plant heads, can see accurate information, analyse it and make better decisions with appropriate timing. In doing so, plant teams can take proactive actions before machine breakdown, enable better coordination during maintenance activities while improving operational efficiency and productivity.
Further using latest technologies like Artificial Intelligence can even assist operators in running their plant with minimal requirement of human intervention, which allows operators to utilise their time in focusing on more critical topics like analysing data to identify further improvements in operation.

Which of your high-efficiency IEC low-voltage motors deliver the best energy savings for cement mills or fans?
Innomotics India offers a range of IEC-compliant low-voltage motors engineered to deliver superior performance and energy savings, particularly for applications such as cement mills, large fans, and blowers. Innomotics has the complete range of IE4 motors from 0.37kW to 1000kW to meet the demands of cement industry. The IE5 range is also available for specific requirements.

Can safe area motors operate safely and efficiently in cement kiln environments?
Yes, safe area motors are designed to operate reliably in these environments without the risk of overheating. These motors have ingress protection that prevents dust, moisture ingress and can withstand mechanical stress. These motors are available in IE3 / IE4 efficiency classes thereby ensuring lower energy consumption during continuous operation. These motors comply with relevant Indian as well as international standards.

How do your SD Severe Duty motors contribute to lower emissions and lower cost in heavy duty cement applications?
Severe duty motors enhances energy efficiency and durability in demanding cement applications, directly contributing to lower emissions and operational costs. With high-efficiency ratings (such as IE3 or better), they reduce power consumption, minimising CO2 output from energy use. Their robust design handles extreme heat, dust and vibration—common in cement environments—ensuring reliable performance and fewer energy losses.
These motors also lower the total cost of ownership by reducing downtime, maintenance and replacement frequency. Their extended service life and minimal performance degradation help cement plants meet sustainability targets, comply with emissions regulations and improve overall energy management—all while keeping production consistent and cost-effective.

What pump, fan or compressor drive upgrades have shown approximately 60 per cent energy savings in industrial settings and can be replicated in cement plants?
In the cement industry, the primary high-power applications are fans and mills. Among these, fans have the greatest potential for energy savings. Examples, the pre-heater fan, bag house fan, and cooler fans. When there are variations in airflow or the need to maintain a constant pressure in a process, using a variable speed drive (VSD) system is a more effective option for starting and controlling these fans. This adaptive approach can lead to significant energy savings. For instance, vanes and dampers can remain open while the variable frequency drive and motor system manage airflow regulation efficiently.

Concrete

We conduct regular internal energy audits

Published

2 days ago

October 10, 2025

admin

Shaping the future of low-carbon cement production involves integrating renewables, digitalisation and innovative technologies. Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, gives us a detailed account of how.

In an industry where energy consumption can account for a significant portion of operating costs, cement manufacturers are under increasing pressure to adopt sustainable practices without compromising efficiency. Nuvoco Vistas has taken a decisive step in this direction, leveraging digitalisation, renewable energy and innovative technologies to drive energy efficiency across its operations. In this exclusive conversation, Uma Suryam, SVP and Head Manufacturing – Northern Region, Nuvoco Vistas, shares its approach to energy management, challenges of modernising brownfield plants and its long-term roadmap to align efficiency with India’s net-zero vision.

How has your company improved energy efficiency over the past five years?
Over the past five years, we have prioritised energy conservation by enhancing operational efficiency and scaling up renewable energy adoption. Through strategic fuel mix optimisation, deployment of cleaner technologies, and greater integration of renewables, we have steadily reduced our environmental footprint while meeting energy needs sustainably.
Technological upgrades across our plants have further strengthened efficiency. These include advanced process control systems, enhanced trend analysis, grinding media optimisation and the integration of solar-powered utilities. Importantly, grid integration at our key plants has delivered significant cost savings and streamlined energy management.
A notable milestone has been the expansion of our solar power capacity and Waste Heat Recovery Systems (WHRS). Our solar power capacity has grown from 1.5 MW in FY 2021–22 to 5.5 MW, while our WHRS capacity has increased from 44.7 MW to 49 MW, underscoring our commitment to sustainable energy solutions.

What technologies or practices have shown the highest energy-saving potential in cement production?
One of our most significant achievements in advancing energy efficiency has been the successful commissioning of a 132 KV Grid Integration Project, which unified three of our major manufacturing units under a single power network. This milestone, enabled by a dedicated transmission line and a state-of-the-art Line-In Line-Out (LILO) substation, has transformed our energy management and operational capabilities.
With this integration, we have substantially reduced our contract demand, eliminated power disruptions, and enhanced operational continuity. Supported by an optical fibre network for real-time communication and automation, this project stands as a testament to our innovation-led manufacturing excellence and underscores Nuvoco’s vision of building a safer, smarter, and sustainable world.

What role does digitalisation play in achieving energy efficiency in your operations?
Digitalisation plays a transformative role in driving energy efficiency across our operations. At Nuvoco, we are leveraging cutting-edge technologies and advanced digital tools to enhance productivity, optimise energy consumption and strengthen our commitment to sustainability and employee safety.
We are developing AI-enabled dashboards to optimise WHRS and kiln operations, ensuring maximum efficiency. Additionally, our advanced AI models evaluate multiple operational parameters — including fuel pricing, moisture content and energy output — to identify the most cost-effective fuel combinations in real time. These initiatives are enabling data-driven decision-making, improving operational excellence and reducing our environmental footprint.

What is your long-term strategy for aligning energy efficiency with decarbonisation goals?
As part of India’s climate action agenda, the cement sector has laid out a clear decarbonisation roadmap to achieve net-zero CO2 emissions by 2070. At Nuvoco, we view this as both a responsibility and an opportunity to redefine the future of sustainable construction. Our long-term strategy focuses on aligning energy efficiency with decarbonisation goals by embracing innovative technologies, alternative raw materials and renewable energy solutions.
We are making strategic investments to scale up solar power installations and enhance our renewable energy mix significantly by 2028. These initiatives are a key part of our broader vision to reduce Scope 2 emissions and strengthen our contribution to India’s net-zero journey, while continuing to deliver innovative and sustainable solutions to our customers.

How do you measure and benchmark energy performance across different plants?
We adopt a comprehensive approach to measure and benchmark energy performance across our plants. Key metrics include Specific Heat Consumption (kCal/kg of clinker) and Specific Power Consumption (kWh/tonne of cement), which are continuously tracked against Best Available Technology (BAT) benchmarks, industry peers and global standards such as the WBCSD-CSI and CII benchmarks.
To ensure consistency and drive improvements, we conduct regular internal energy audits, leverage real-time dashboards and implement robust KPI tracking systems. These tools enable us to compare performance across plants effectively, identify optimisation opportunities and set actionable targets for energy efficiency and sustainability.

What are the key challenges in adopting energy-efficient equipment in brownfield cement plants?
Adopting energy-efficient technologies in brownfield cement plants presents a unique set of challenges due to the constraints of working within existing infrastructure. Firstly, the high capital expenditure and relatively long payback periods often require careful evaluation before investments are made. Additionally, integrating new technologies with legacy equipment can be complex, requiring significant customisation to ensure seamless compatibility and performance.
Another major challenge is minimising production disruptions during installation. Since brownfield plants are already operational, upgrades must be planned meticulously to avoid affecting output. In many cases, space constraints in older facilities add to the difficulty of accommodating advanced equipment without compromising existing layouts.
At Nuvoco, we address these challenges through a phased implementation approach, detailed project planning and by fostering a culture of innovation and collaboration across our plants. This helps us balance operational continuity with our commitment to driving energy efficiency and sustainability.

Concrete

Enlight Metals Supplies 3,200 Tonne of Steel for Navi Mumbai Airport

The airport is set to become Asia’s largest air connectivity hub.

Published

2 days ago

October 10, 2025

admin

Enlight Metals has supplied 3,200 metric tonne of steel for the newly inaugurated Navi Mumbai International Airport, marking a major contribution to one of India’s largest infrastructure projects and reinforcing the company’s commitment to supporting national development.

The Navi Mumbai International Airport, developed under a Public-Private Partnership led by the Adani Group, was inaugurated today by Prime Minister Narendra Modi. The airport is set to become Asia’s largest air connectivity hub, enhancing regional connectivity, boosting economic growth, and expanding trade opportunities. Prime Minister Modi described the project as a “glimpse of Viksit Bharat,” highlighting its transformative impact on infrastructure and development in the region.

“The supply of 3,200 metric tonne of steel for this key project aligns with our focus on supporting critical infrastructure development through reliable and timely metal sourcing. Enlight Metals is committed to enhancing transparency and efficiency in the steel supply chain, contributing to projects integral to India’s growth objectives,” said Vedant Goel, Director, Enlight Metals.

Enlight Metals has implemented technology-driven solutions to strengthen supply chain efficiency, ensuring consistent availability of construction materials for large-scale projects nationwide. Its contribution to the Navi Mumbai International Airport underscores the company’s growing role in supporting India’s infrastructure development initiatives.

This milestone reflects Enlight Metals’ ongoing engagement in delivering quality materials and timely services for major national projects, further cementing its position as a reliable partner in India’s infrastructure sector